sugarcane biorefineries the stone age did not end for lack of stone, and the oil age will end long...
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Sugarcane Biorefineries
The Stone Age did not end for lack of The Stone Age did not end for lack of stone, and the Oil Age will end long stone, and the Oil Age will end long
before the world runs out of oil.before the world runs out of oil.Sheikh Zaki Yamani, Saudi Arabia oil ministerSheikh Zaki Yamani, Saudi Arabia oil minister
Integrated biorefineries
• By 2050By 2050 75% of $2,000 billion chemical industry biobased75% of $2,000 billion chemical industry biobased Large opportunities for all participants in the value-chain, Large opportunities for all participants in the value-chain,
including suppliers of renewable resourcesincluding suppliers of renewable resources
• Biobased versus inorganic catalysisBiobased versus inorganic catalysis High yield, purity and specificityHigh yield, purity and specificity Water-based, low T, low PWater-based, low T, low P New product spectrumNew product spectrum Large reduction in environmental compliance costsLarge reduction in environmental compliance costs
Why bioproducts (DuPont)?
Renewable & widespread Renewable & widespread sustainable and reliable resourcesustainable and reliable resource
Low toxicity & flammability Low toxicity & flammability inherent safe and benign processinherent safe and benign process
Good raw material economics Good raw material economics comparable to petrochemicalscomparable to petrochemicals
Unique & rich functionality Unique & rich functionality novel materials, oxygen built-innovel materials, oxygen built-in
Requires new technology Requires new technology opportunities for proprietary positionopportunities for proprietary position
Chad says so: “25% renewable in 2010”Chad says so: “25% renewable in 2010”
Requirements
• Cost efficient raw materialsCost efficient raw materials Carbon, energy and waterCarbon, energy and water
• Efficient catalysisEfficient catalysis Enzymatic catalysis, fermentation, in plantaEnzymatic catalysis, fermentation, in planta
• Efficient separation processesEfficient separation processes Water based separationWater based separation
• Smart system integrationSmart system integration Capital utilization for smaller plantsCapital utilization for smaller plants New integrated product modelNew integrated product model
Criteria for a good feedstock
• Perennial cropPerennial crop Reduced mechanical inputReduced mechanical input
• High biomass densityHigh biomass density Reduced transport energyReduced transport energy
• High water efficiencyHigh water efficiency• High fertilizer efficiencyHigh fertilizer efficiency
Reduced energy input and environmental impactReduced energy input and environmental impact
• Readily processedReadily processed Reduced process energy input and capital costsReduced process energy input and capital costs
• Inexpensive relative to qualityInexpensive relative to quality• Supply of energy for processingSupply of energy for processing
Feedstock versus process
EnergyEnergy ChemicalsChemicals
ProductionProductionMillableMillable
StalkStalk
FeedstockFeedstock 52%52% 47%47%
ProcessProcess 48%48% 53%53%
Renewable source of process energy is as important as feedstock indeveloping bio-based products.
Sugarcane has a unique advantage through bagasse.
-15.00
-10.00
-5.00
0.00
5.00
10.00
Sug
arca
ne
Cor
n
Sug
ar b
eet
En
erg
y in
pu
t (M
J/kg
mo
no
sacc
har
ide)
Agricultural production
Processing
Substituted products
TOTAL
-0.80
-0.60
-0.40
-0.20
0.00
0.20
0.40
0.60
0.80
1.00
1.20
1.40
Sug
arca
ne
Cor
n
Sug
ar b
eet
Gre
enh
ou
se g
as e
mis
sio
ns
(kg
CO
2(eq
)/kg
mo
no
sacc
har
ide)
Field emissionsAgricultural productionProcessingSubstituted productsTOTAL
Corn
Cane
LAfermentationpurification
gypsumbiomass
PLApolymerisation
Sug
crushing
Wet-millingenz hydrolysis
8.8+0.6 MJ
12.8+0.4 MJ14.9+11.4 MJ
GlutenOil
Fibre32 MJ
28.4+5.3 MJ
Corn
Cane
PLA production
Ethanol
Energy gainEnergy gain Price per bbl oil eq.Price per bbl oil eq.
GasolinGasolin 0.80.8 US $50US $50
US cornUS corn 1.31.3 US $60-75 ($2.6/bu)US $60-75 ($2.6/bu)
Cane juiceCane juice 8-108-10 US $60-75 (10c/lb)US $60-75 (10c/lb)
SugarBoosterSugarBooster 10-1510-15 US $40-60, 2015US $40-60, 2015
Corn stoverCorn stover 5.35.3 2020?2020?
BagasseBagasse Very highVery high 2020?2020?
Switch grassSwitch grass 2.62.6 2025?2025?
Lignocellulosics
Lignocellulosic ethanol
• Bagasse is to sugar as coal is to oilBagasse is to sugar as coal is to oil Excellent source of heat and electricityExcellent source of heat and electricity Suited for some C5 (e.g., furfural) and lignin productsSuited for some C5 (e.g., furfural) and lignin products Need quantum leap in technology to achieve meaningful Need quantum leap in technology to achieve meaningful
ethanol economyethanol economy
• Limited quantity, seasonalityLimited quantity, seasonality Current thermochemical approaches non-viableCurrent thermochemical approaches non-viable Need enzymatic approach or high value by-productsNeed enzymatic approach or high value by-products Realize environmental value though co-genRealize environmental value though co-gen Use coal-to-liquid and burn the bagasseUse coal-to-liquid and burn the bagasse
Ethanol: the worst possible product
Crude Petrol40 GJ 40 GJ$480 $500
Sugar EtOH18 GJ 27 GJ$200 $400 ($600oe)
In conventional combustion engines,no premium for higher purity
Chemicals Spot price
Ethylene $ 950/tPropylene $ 1100/tStyrene $ 1290/t
LDPE $ 1350/tPP $ 1260/tPS $ 1420/tABS $ 1600/t
23.4.2007
Political imperatives
• Indirect farm subsidiesIndirect farm subsidies• Resource securityResource security• Environmental impactEnvironmental impact
Passenger cars <8% of Australian GHG emissionsPassenger cars <8% of Australian GHG emissions Existing technology could half thisExisting technology could half this Several future alternativesSeveral future alternatives
Political imperatives
• Indirect farm subsidiesIndirect farm subsidies• Resource securityResource security• Environmental impactEnvironmental impact
Passenger cars <8% of Australian GHG emissionsPassenger cars <8% of Australian GHG emissions Existing technology could half thisExisting technology could half this Several future alternativesSeveral future alternatives
• Ease of introductionEase of introduction Readily controlled by policyReadily controlled by policy Existing technologyExisting technology Easy to explainEasy to explain
• Path to better products?Path to better products?
Efficient catalysts
• Enzyme bio-catalysisEnzyme bio-catalysis Low cost, flexibleLow cost, flexible Limited product range (e.g., co-factor needs)Limited product range (e.g., co-factor needs)
• FermentationFermentation Fast development, large engineering potentialFast development, large engineering potential Broad product rangeBroad product range
• In plantaIn planta Potentially lowest costPotentially lowest cost Long lead time, downstream purificationLong lead time, downstream purification
Metabolic engineering
We are studying microbes as "programmable" We are studying microbes as "programmable" manufacturing factories to make chemicals, manufacturing factories to make chemicals, monomers and polymers from different nutrient monomers and polymers from different nutrient feedstocks. Current feedstocks for these materials feedstocks. Current feedstocks for these materials are petrochemicals from oil. We are programming are petrochemicals from oil. We are programming microbes to make very sophisticated polymer microbes to make very sophisticated polymer building blocks and molecules out of simple, building blocks and molecules out of simple, renewable feedstocks, like glucose and methane.renewable feedstocks, like glucose and methane.
Chad Holliday, Chairman & CEO – DuPont, Chad Holliday, Chairman & CEO – DuPont, Boston Chief Executive Club, Sept 99.Boston Chief Executive Club, Sept 99.
• Classical biotechnology• Random mutations• Process optimisation• Fixed product range
• Classical biotechnology• Random mutations• Process optimisation• Fixed product range
• Genetic engineering• New products
PDO
• Classical biotechnology• Random mutations• Process optimisation• Fixed product range
• Genetic engineering• New products
PDO
• Enzyme engineering• Improved kinetics
• Classical biotechnology• Random mutations• Process optimisation• Fixed product range
• Genetic engineering• New products
PDO
• Enzyme engineering• Improved kinetics
• Metabolic engineering• Pathway redesign• Control redesing
Metabolic engineering
• From retrofitting to green field designFrom retrofitting to green field design Genetic engineering Genetic engineering systems & synthetic biology systems & synthetic biology
• PDOPDO 7 years, 15 staff using conventional metabolic engineering7 years, 15 staff using conventional metabolic engineering
• Succinic acidSuccinic acid 3 years, 10 staff using systems biology3 years, 10 staff using systems biology
• Amino acidsAmino acids 2-3 years, 3 staff using synthetic biology followed by 2-3 years, 3 staff using synthetic biology followed by
systems biology systems biology
Real challenges
• One 50,000 tpa facilityOne 50,000 tpa facility $50m in R&D$50m in R&D $75-150m in capital cost$75-150m in capital cost 7-10 years to market7-10 years to market
• IntegrationIntegration End-users expect complete solutionsEnd-users expect complete solutions Existing chemical industry benefits immensely from process Existing chemical industry benefits immensely from process
and product integrationand product integration Market penetrationMarket penetration
50% lower production price for replacement products50% lower production price for replacement products Distinct advantages for new productsDistinct advantages for new products
• Need collaborations to succeed!Need collaborations to succeed!
Conclusions
• Over the next generationOver the next generation $2,000b chemical industry will become bio-based$2,000b chemical industry will become bio-based Large opportunities throughout the value chainLarge opportunities throughout the value chain
• Sugarcane ideal biomass cropSugarcane ideal biomass crop Bagasse provides inexpensive, renewable energyBagasse provides inexpensive, renewable energy
• Australia can competeAustralia can compete Century long tradition of competing through leading Century long tradition of competing through leading
sugarcane technologysugarcane technology Strong biotech infrastructureStrong biotech infrastructure Portal to growing markets in AsiaPortal to growing markets in Asia